Form fitting garments and methods for making same

ABSTRACT

A seamless base layer garment can be made using a whole garment-rectilinear knitting machine. The garment can be knitted on the whole garment-rectilinear knitting machine using a yarn comprising an elastic core strand, and a plurality of cover strands. One cover strand can be made of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, and/or modacrylic. Another cover strand can be made of silver, copper, ceramic fiber and/or carbon fiber. The garment can be form fitting, and have the feel of a second skin to the wearer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/121,158, filed Feb. 26, 2015, and which is incorporated herein by reference.

TECHNICAL FIELD OF INVENTION

The present invention relates to textiles, and methods for manufacturing same. An embodiment of the invention comprises base-layer garments with improved technical features, and methods for manufacturing same.

BACKGROUND OF INVENTION

Base-layer garments are typically manufactured with specific knitting machines, i.e. circular machines (known in Italian as “macchine circolari”) or looms. However, a disadvantage of garments manufactured on circular machines and looms is that they generally cannot be seamless.

SUMMARY OF INVENTION

One object of the invention is to provide a method of making a form fitting seamless base-layer garment. Another object of the present invention is to provide base-layer garments having improved technical features, such as improved elasticity, breathability, comfort, fire resistance, and/or antimicrobial properties. These and other objects of the invention can be achieved in various embodiments of the invention described herein.

One embodiment of the invention comprises a garment manufactured through the utilization of a seamless and complete whole garment manufacturing process using a yarn comprised of a silver fiber and other fibers of various nature, such as natural, artificial, synthetic, elastic, fireproof fibers.

Another embodiment of the invention comprises a form fitting base-layer garment that can have the feel of a second skin to the wearer. The garment can be worn as underwear or a base layer for athletes, such as in skiing and cycling. The garment can also be used in the medical field, or as a fireproof garment.

Another embodiment of the invention comprises a yarn for making a base layer garment comprising an elastic core strand, and first and second cover fibers wrapped around the core strand. The core strand can be comprised of elastane (also known as spandex and sold by E. I. du Pont de Nemours and Company under the name “LYCRA”). The first cover can be comprised of a strand of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber (known as “FR viscose”), or modacrylic or a combination of said fibers. For example, the first cover can be comprised of strands of polystere and polypropylene, polypropylene and wool, or polyester and polyamide. The second cover can be comprised of a strand of silver, copper, ceramic fiber, carbon fiber, or a combination thereof. For example, the second cover can be comprised of silver and ceramic fiber. Another embodiment of the invention comprises a garment made from said yarn.

Another embodiment of the invention comprises a garment comprised of a yarn comprising elastane, polyester and silver fibers. The elastane fiber can be a core strand, and the polyester fiber and silver fiber can be wrapped around the elastane core fiber.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and polypropylene and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and polyamide and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and wool and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and cotton and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and viscose and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and fire resistant viscose and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and aramid and silver fibers wrapped around the elastane core.

Another embodiment of the invention comprises a garment comprised of a yarn comprising an elastane core strand, and modacrylic and silver fibers wrapped around the elastane core.

According to another embodiment of the invention, yarns made out of fiber mixes that include silver and fibers of other nature (natural, artificial, synthetic, elastic, fireproof) are used to manufacture knitted underwear garments, produced though a manufacturing technique that allows for the creation of seamless, complete (that requires no assembly) and 3D garments.

According to another embodiment of the invention, knitted underwear and other base layer garments can be made through manufacturing procedures that allow for the creation of seamless, whole (that requires no assembly) and 3D garments, using electronic, rectilinear machines with subtleties within the range of 12 gauge to 18 gauge fineness.

According to another embodiment of the invention, the continuity of the yarn, and the presence of silver on each knitted garment, gives the garment high antibacterial capacity which increases significantly when it is heated from a natural source such as the body temperature. In addition, the conductive silver allows for the dissipation of electrostatic charges throughout the body of the wearer.

According to another embodiment of the invention, garments can be produced that allow for the insertion of areas that have different features (for example areas made with textiles that have different thicknesses) or for the insertion of padding without affecting breathability and comfort. In addition, the garments can have ventilation zones to remove heat if necessary or, alternatively, thermal pockets to trap heat.

According to another embodiment of the invention, a garment is made of a yarn comprising an elastic core strand, a first and second cover strands wrapped around the elastic core strand. The first cover strand is comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic, or a combination thereof. The second cover strand is comprised of silver, copper, ceramic fiber or carbon fiber, or a combination thereof.

According to another embodiment of the invention, the elastic core strand comprises elastane.

According to another embodiment of the invention, the first cover strand is wrapped around the elastic core strand in an S-twist and the second cover is wrapped around the elastic core strand in a Z-twist.

According to another embodiment of the invention, the first cover strand is wrapped around the elastic core strand in a Z-twist and the second cover is wrapped around the elastic core strand in an S-twist.

According to another embodiment of the invention, the yarn further comprises a third cover strand wrapped around the elastic core strand. The third cover strand can be comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic, or combinations thereof.

According to another embodiment of the invention, the first cover strand and the third cover strand are wrapped around the elastic core strand in opposite helical orientations, and the second cover strand is positioned intermediate the first cover strand and the third cover strand.

According to another embodiment of the invention, the garment includes ventilation areas adapted for removing heat.

According to another embodiment of the invention, the garment includes thermal pockets adapted for retaining heat.

According to another embodiment of the invention, the garment is seamless.

According to another embodiment of the invention, the garment is form-fitting.

According to another embodiment of the invention, a method of making a seamless base layer garment includes the steps of providing a whole garment-rectilinear knitting machine, and knitting the garment on the whole garment-rectilinear knitting machine using a yarn comprising an elastic core strand, and first and second cover strands wrapped around the elastic core strand. The first cover strand is comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, and/or modacrylic, and the second cover strand is comprised of silver, copper, ceramic fiber, and/or carbon fiber.

According to another embodiment of the invention, the core strand, the first cover strand and the second cover strand are twisted together on a distaff.

According to another embodiment of the invention, there is no interruption of thread during the knitting of the garment on the whole garment-rectilinear machine.

According to another embodiment of the invention, the elastic core strand comprises elastane.

According to another embodiment of the invention, a yarn for making a base layer garment comprises an elastic core strand, and a plurality of cover strands wrapped around the elastic core strand. A first cover strand can be comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, and/or modacrylic. A second cover strand can be comprised of silver, copper, ceramic fiber, and/or carbon fiber. The elastic core strand can be comprised of elastane.

According to another embodiment of the invention, the yarn includes a third cover strand wrapped around the elastic core strand. The third cover strand can be comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, and/or modacrylic.

According to another embodiment of the invention, the yarn comprises an elastic core strand comprised of elastane, a first cover strand comprised of polyester, a second cover strand comprised of silver, and a third cover strand comprised of polypropylene.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a yarn according to a preferred embodiment of the invention;

FIG. 2 is a schematic view of a yarn according to another preferred embodiment of the invention; and

FIG. 3 is a perspective view of a garment according to another preferred embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF INVENTION

A yarn according to a preferred embodiment of the invention is illustrated in FIG. 1, and shown generally at reference numeral 10. As shown in FIG. 1, the yarn 10 comprises a core strand 12, and a first cover fiber 14 and a second cover fiber 16 wrapped around the core strand 12. The cover fibers 14, 16 can be wrapped around the core 12 in a helical configuration, with the first cover 14 in an S-twist and the second cover 16 in a Z-twist, as shown in FIG. 1. Alternatively, the covers 14, 16 can be arranged in different twist arrangements and geometries. For example, the first cover 14 can have a Z-twist, while the second cover 16 has an S-twist. In another alternative embodiment, both the first cover 14 and the second cover 16 are wrapped around the core 12 in an S-twist.

The core strand 12 is comprised of elastane (also known as spandex and lycra). The first cover 14 can be comprised of a strand of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber (known as “FR viscose”), or modacrylic. The second cover 16 can be comprised of a strand of silver, copper, ceramic fiber, carbon fiber, or a combination thereof. For example, the second cover 16 can be comprised of silver and ceramic fiber. Preferably, the second cover 16 is comprised of a strand of silver. The yarn 10 preferably has a yarn count of 16 tex to 55 tex.

A yarn according to another preferred embodiment of the invention is illustrated in FIG. 2, and shown generally at reference numeral 20. As shown in FIG. 2, the yarn 20 comprises a core strand 22, and a first cover fiber 24, a second cover fiber 25 and a third cover fiber 26 wrapped around the core strand 22. The first and second cover fibers 24, 25 are wrapped around the core 22 in a helical configuration, with the first cover fiber 24 in a Z-twist and the second cover fiber 25 in an S-twist, as shown in FIG. 2. The third cover fiber extends around the core 22 in an S-twist, intermediate the first and second cover strands 24, 25, as shown in FIG. 2. Alternatively, the covers 24, 25, 26 can be arranged in different twist arrangements and geometries. For example, the first cover 24, second cover 25 and third cover 26 can be wrapped around the core 22 in an S-twist. The yarn 20 preferably has a yarn count of 16 tex to 55 tex.

The core strand 22 is comprised of elastane (also known as spandex and lycra). The first and second cover fibers 24, 25 can be comprised of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber (known as “FR viscose”), or modacrylic. Preferably, the first cover fiber 24 comprises polyester, and the second cover 25 comprises polypropylene.

In another preferred embodiment, the first cover fiber 24 comprises polyester and the second cover fiber 25 comprises polyamide. In another preferred embodiment, the first cover fiber 24 comprises polypropylene, and the second cover fiber 25 comprises polyamide. In another preferred embodiment, the first cover fiber 24 comprises wool, and the second cover fiber 25 comprises polypropylene. In another preferred embodiment, the first cover fiber 24 comprises polyester, and the second cover fiber 25 comprises wool. In another preferred embodiment, the first cover fiber 24 comprises polyamide, and the second cover fiber 25 comprises wool. In another preferred embodiment, the first cover fiber 24 comprises wool, and the second cover fiber 25 comprises cotton. In another preferred embodiment, the first cover fiber 24 comprises viscose, and the second cover fiber 25 comprises cotton. In another preferred embodiment, the first cover fiber 24 comprises aramid, and the second cover fiber 25 comprises modacrylic. In another preferred embodiment, the first cover fiber 24 comprises FR viscose, and the second cover fiber 25 comprises aramid.

The third cover fiber 26 is comprised of silver, copper, ceramic fiber, or carbon fiber, or a combination thereof. For example, the third cover 26 can be comprised of silver and ceramic fiber. Preferably, the third cover 26 comprises a silver fiber.

According to an embodiment of the invention, a base layer garment can be made utilizing any of the above described yarns 10, 20 in a whole garment-rectilinear machine (known in Italian as “macchina rettilinea a capo completo”), such as the machine sold by Japanese manufacturer Shima Seiki under the name “MACH2S.” The use of whole garment-rectilinear machines with yarns 10, 20 produce seamless garments.

Whole garment-rectilinear machines are typically used with specific types of textiles. The textiles commonly used with whole garment-rectilinear machines typically lead to garments not suitable to be used as base-layers (often because they are too thick or do not present the necessary technical features). However, the yarns 10, 20 of the present invention can be knitted by whole garment-rectilinear machines to produce totally seamless base-layer garments which due to their high level of elasticity show a significant change in their grams per inch ratio and become much thinner when worn on a person's body. The fibers of the yarn 10 or 20 can be twisted together on a distaff so as to make the yarn 10, 20 appear like one fiber (“ritorti insieme su rocca in un unico filato”).

The combination of the yarn 10, 20 of the present invention and the whole garment-rectangular machine manufacturing process can produce garments, such as the long sleeve t-shirt 30 shown in FIG. 3, with high performance in various ways, such as elasticity, breathability, thermo-regulatory properties, antimicrobial properties, and comfort. The garments are seamless and form fitting. The garments can adhere perfectly around the body of the wearer, providing complete freedom of movement for the wearer. In addition, such adhesion facilitates the expulsion of perspiration of the wearer.

The garments have the feel of a second-skin to the wearer. Garments made by the process and yarns 10, 20 of present invention can provide high antibacterial properties and regulate temperature.

There is no interruption of thread in the manufacturing process. The inserted yarn on distaff remains continuous in all phases of the process, allowing the thread and silver fiber (preferably comprised of 99% pure silver) in each garment to be produced without interruption. Alternatively, copper fiber can be used in place of silver. The continuity of the wire and the presence of silver or copper in the garment can confer to the garment high antibacterial capabilities that in turn increase significantly when the garment is heated by a natural source such as the body heat of the wearer.

The accumulation and temperature maintenance, the high level of elasticity of the yarn 10, 20 and the particular manufacturing process of the seamless and whole 3D garment, facilitates the expulsion of sweat and speeds up the drying of the garment, leaving continuously dry skin. The silver conductive characteristics also allow for the dissipation of electrostatic charges from the body.

Articles made with the machining process and yarns 10, 20 of the present invention can include knitted underwear; clothing for dogs, horses, rabbits, cats and other animals; interior linings for work gloves, base layer garments for wearing during athletic and medical activities; clothing for the treatment of hyperhidrosis; socks and thermo heated gloves; interior layers for technical clothing; interior layers for gloves and sock fabrics; blankets; pillowcases; and covers. There are many ranges of products obtainable according to different requirements, including the use of fireproof yarns for protective clothing.

A form fitting garment and method of making same are described above. Various changes can be made to the invention without departing from its scope. The above description of embodiments of the invention are provided for the purpose of illustration only and not limitation—the invention being defined by the claims and equivalents thereof. 

What is claimed is:
 1. A garment comprised of a yarn comprising: (a) an elastic core strand; (b) a first cover strand wrapped around the elastic core strand, the first cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic; and (c) a second cover strand wrapped around the elastic core strand, the second cover strand comprising at least one material selected from the group consisting of silver, copper, ceramic fiber, and carbon fiber.
 2. The garment according to claim 1, wherein the elastic core strand comprises elastane.
 3. The garment according to claim 1, wherein the first cover strand is wrapped around the elastic core strand in an S-twist and the second cover is wrapped around the elastic core strand in a Z-twist.
 4. The garment according to claim 1, wherein the first cover strand is wrapped around the elastic core strand in a Z-twist and the second cover is wrapped around the elastic core strand in an S-twist.
 5. The garment according to claim 1, wherein the yarn further comprises a third cover strand wrapped around the elastic core strand, the third cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic.
 6. The garment according to claim 5, wherein the first cover strand and the third cover strand are wrapped around the elastic core strand in opposite helical orientations, and the second cover strand is positioned intermediate the first cover strand and the third cover strand.
 7. The garment according to claim 1, further comprising ventilation areas adapted for removing heat.
 8. The garment according to claim 1, further comprising thermal pockets adapted for retaining heat.
 9. The garment according to claim 1, wherein the garment is totally seamless.
 10. The garment according to claim 1, wherein the garment is form-fitting.
 11. A method of making a seamless base layer garment comprising the steps of: (a) providing a whole garment-rectilinear knitting machine; (b) providing a yarn comprised of: (i) an elastic core strand, (ii) a first cover strand wrapped around the elastic core strand, the first cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic, and (iii) a second cover strand wrapped around the elastic core strand, the second cover strand comprising at least one material selected from the group consisting of silver, copper, ceramic fiber, and carbon fiber; and (c) knitting the yarn on the whole garment-rectilinear knitting machine to produce a seamless base layer garment.
 12. The method according to claim 11, wherein the core strand, the first cover strand and the second cover strand are twisted together on a distaff.
 13. The method according to claim 11, wherein there is no interruption of thread in the step of knitting the yarn on the whole garment-rectilinear machine.
 14. The method according to claim 11, wherein the whole garment-rectilinear knitting machine has a range of twelve gauge to eighteen gauge fineness.
 15. The method according to claim 11, wherein the yarn further comprises a third cover strand wrapped around the elastic core strand, the third cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic, and further wherein the first cover strand and the third cover strand are wrapped around the elastic core strand in opposite helical orientations, and the second cover strand is positioned intermediate the first cover strand and the third cover strand.
 16. A yarn for making a base layer garment comprising: (a) an elastic core strand; (b) a first cover strand wrapped around the elastic core strand, the first cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic; and (c) a second cover strand wrapped around the elastic core strand, the second cover strand comprising at least one material selected from the group consisting of silver, copper, ceramic fiber, and carbon fiber.
 17. The yarn according to claim 16, wherein the yarn has a count of 16 tex to 55 tex.
 18. The yarn according to claim 16, wherein the elastic core strand comprises elastane.
 19. The yarn according to claim 16, further comprising a third cover strand wrapped around the elastic core strand, the third cover strand comprising at least one material selected from the group consisting of polyester, polypropylene, polyamide, wool, cotton, viscose, aramid, flame retardant viscose fiber, or modacrylic.
 20. The yarn according to claim 19, wherein the elastic core strand comprises elastane, the first cover strand comprises polyester, the second cover strand comprises silver, and the third cover strand comprises polypropylene. 